Wall structure for buildings



Nov- 2 1962 R. T. RAY 3,065,575

WALL STRUCTURE FOR BUILDINGS Filed June 6. 1958 s Sheets-Sheet 1 T 14/: H 16 l Fit h a 1e I' M. W) at i j 2 l i illl Nov. 27, 1962 R. T. RAY

WALL STRUCTURE FOR BUILDINGS 3 Sheets-Sheet 2 Filed June 6, 1958 Nov. 27, 1962 R. T. RAY

WALL STRUCTURE FOR BUILDINGS- 3 Sheets-Sheet 5 Filed June 6. 1958 q Q .W I IA a //7 re fan F0 Ae/f flay III as fr. .5

v I I Q r T5- ll- United States Patent 3,065,575 WALL STRUCTURE FOR BUILDINGS Robert T. Ray, Albany, 6a., assignor of ten percent to Bernard W. Downs Filed June 6, 1958, Ser. No. 749,403 4 Claims. (Cl. 50-405) This invention relates to new and useful improvements in the art of construction of walls in residential and/or commercial buildings, and the principal object of the invention is to facilitate construction of such walls with ease and convenience, at low cost, and without the usual requirement for skilled labor.

The invention attains this object by the provision of prefabricated metallic frame sections which may be quickly and easily installed in place and to which suitable conventional wall forming panels or other similar material may be applied with equal expediency in order to produce a finished wall.

The teachings of the invention are applicable to both interior and exterior wall construction, and the wall forming material may be of any desired type, such as for example, gypsum board, expanded metal lath for plastering, blocks of tile or stone, or any other similar material such as is readily available on the open market.

An important feature of the invention, therefore, resides in the structural arrangement of the prefabricated metallic frame sections whereby such sections are adapted for association with the various types of wall forming material as above outlined, while another important feature of the invention resides in the provision of means, integral with the frame sections, for retaining the wall forming material thereon. Another important feature of the invention resides in its ability for association with monolithically poured concrete columns or beams for materially strengthening the wall structure, as well as in its ability for use with either concrete or wooden floors and ceilings.

Another important feature of the invention resides in the provision of means for accommodating panels of insulating material and sheets of vapor blocking material on the prefabricated frame sections, in addition to the wall forming material itself, when necessary, so that the structure is highly resistant to the passage of heat, cold, vapors and moisture therethrough.

With the foregoing more important objects and features in View and such other objects and features as may become apparent as this specification proceeds, the invention will be understood from the following description taken in conjunction with the accompanying drawings, wherein like characters of reference are used to designate like parts, and wherein for illustrative purposes:

FIGURE 1 is a fragmentary elevational view of one of the prefabricated frame sections in accordance with the invention;

FIGURE 2 is a horizontal sectional view, taken substantially in the plane of the line 2--2 in FIGURE 1;

FIGURE 3 is a vertical sectional detail, taken substantially -in the plane of the line 3-3 in FIGURE *1;

' FIGURE 4 is a fragmentary isometric view showing the arrangement of the abutment tabs and detents on one of the horizontal flanges of a frame section;

FIGURE 5 is a fragmentary vertical sectional view of the finished wall embodying the frame section therein;

FIGURE 6 is a fragmentary elevational detail showing one of the abutment tabs with its pair of detents;

FIGURE 7 is a fragmentary vertical sectional view illustrating a somewhat modified embodiment of the invention;

i FIGURE 8 is a fragmentary elevational view on a reduced scale, of the wall structure shown in FIGURES;

FIGURE 9 is a horizontal sectional detail in fragmentary form, showing connection of two frame sections to a wall reinforcing column;

FIGURE 10 is a fragmentary vertical sectional view,

similar to that shown in FIGURE 5, but illustrating the' invention as being embodied in an exterior wall;

FIGURE ll is a fragmentary sectional view, similar to that shown in FIGURE 9 but showing a modified connection of the frame section to a column; and

FIGURE 12 is a fragmentary perspective view of another modified form of the invention.

Referring now to the accompanying drawings in detail,

particularly to FIGURES 1-6 and 8, the invention resides in the provision of a prefabricated metallic wall section Each of the frame sections 12 embodies in its construetion a plurality of vertical members 13 which are preferably channel-shaped or U-shaped in cross-section together with a plurality of horizontal members 14 which are preferably L-shaped in cross-section, such as structural angle bars. As is best shown in FIGURE 2, the horizontal members '14 are secured by their vertical flanges 14a to the vertical members 13, the members 14 being provided at both sides of the members 13, with the horizontal flanges 14b of the members 14 projecting outwardly from the members 13, as illustrated. Each section 12 may consist of any suitable number of the members 13, 14, secured together in any suitable manner, such as by welding or by the screws 15 if so preferred.

As is best shown in FIGURE 4, the horizontal flange 14b of each of the horizontal members 14 is provided at longitudinally spaced points thereon with a plurality of substantially T-shaped tabs '16 which are formed integrally with the flange 14b by being struck out therefrom, thereby resulting in the formation of substantially T-shaped recesses 17 in the flange 14b, which recesses have open arms 17a at the outer longitudinal edge of the flange. The tabs 16 are angulated perpendicularly to the flange 14b so that they extend alternately upwardly and downwardly therefrom, and the portions of the flange 14b at opposite sides of the open arm 17a of each recess 17 constitute a pair of detents 18 which are bendable or deformable either upwardly or downwardly from the plane of the flange, as exemplified in FIGURE 6.

A typical arrangement of a wall constructed in accord' ance with the invention is shown in FIGURE 5, wherein it will be noted that the prefabricated frame section 12 has been secured vertically to a suitable floor =19 by means of a plurality of suitable studs, pins, nails, screws or other fastening elements 20, extending into the floor through apertures formed in a mounting channel 21 which is provided at the lower ends of the vertical members 13 of the frame section. The floor 19 may be of concrete as shown, or the invention may be used on a wooden floor with equal facility.

In any event, wall forming panels 22 may then be applied to the frame section 12 by resting their lower edges on the horizontal flanges 14b, the dimensions of the parts being such that the panels 22 fit snugly between the vertically spaced flanges 14b and each such flange is interposed between the lower edge' of the panel which it supports and the upper edge of the next lower panel.

and downturned arrangement of the tabs '16 provides for abutment of the tabs with both panels above and below each flange 14b, as will be clearly understood.

The panels 22 may be in the form of gypsum board, or the like, and upon installation thereof the aforementioned detents '18 are deformed, such as with the use of a hammer or pliers, so that they are bent over the adjacent edge portions of the panels and securely retain the panels in place. The distance of the detents 18 from the abutment tabs 16 may correspond substantially to the thickness of the panels, but preferably it is somewhat less, so that the detents, upon deformation, actually become embedded in the edge portions of the panels and positively prevent their displacement.

A rough coat of plaster 23 may then be applied to the panels 22 and subsequently covered by a finishing coat 24 to complete the wall. As shown, a conventional baseboard 25, moulding 26 and floor covering 27 may be provided. A suitable fill 28 may be used inside the lower portion of the wall structure under the lowermost of the panels 22, and the tabs 16, projecting upwardly from the frame section at the top, may be embedded in a ceiling beam 29 or in the ceiling itself, as the case may be.

The arrangement shown in FIGURE represents that of an interior Wall or partition, wherein the covering material on both sides ofthe wall is substantially the same. In FIGURE a typical arrangement of an exterior Wall is illustrated, wherein the inside of such a wall is the same or substantially the same as already described in connection with FIGURE 5, but wherein the panels 30- at the outside of the wall are in the form of stone blocks, tile, or other similar material.

The panels 30 are retained in place by the deformed detents 18 in abutment with the tabs 16 and the joints between the panels are grouted as indicated at 31.

An insulating panel 32 is provided, preferably between the vertical members .13 and the vertical flanges 14a of the horizontal members 14 at the outside or outer side of the wall, and a vapor blocking sheet 33 of tinfoil, plas tic or other suitable material is provided between the members 13 and the flanges 14a of the members 14 at the inner side of the wall. The sheet 33, the panel 32 and the members '14 are secured to the members 13 by plastic nails 34, or the like.

As already mentioned, the prefabricated frame sections are used in multiples as necessary for the construction of a wall of a given size, and if the wall is equipped with vertical-reinforcing columns as shown at 35 in FIGURES 8 and 9, the adjacent frame sections are abutted against such columns and suitably secured thereto, such as for example, by bolts 36 positioned in apertures formed in the members \13 and screw-threaded into tubular sockets 37 embedded transversely in the columns 35. Alternatively, as shown in FIGURE i l, a pair of strips 37 may be embedded in the column so as to extend vertically and;

project laterally therefrom, and the members 14 of the adjacent frame section may be secured directly to the projecting portions of the strips. In such event the vertical member 13 at the side of the frame section adjacent the column is not employed, and if the span or distance between adjacent columns is such as to require a frame section of some considerable width, the horizontal members 14 of the frame section may be tied together by suitable straps 38 of nylon or other suitable material.

FIGURE 7 illustrates a slightly modified form of the invention wherein the vertical flange 14a of the horizontal member 14 is provided with an outwardly projecting flange or rib 39 having its outer edge coplanar with the tabs 16, thus providing additional abutment means for the wall forming panels, apart from the tabs.

Finally, FIGURE 12 illustrates another modified form of the invention which is adapted for use with expanded metal lath 4% the same being secured to the vertical members 13 by bendable tongues 41 which are struck out from the members 13, as will be. apparent. In this event the horizontal members 14 are not provided with the tabs 16 and detents '18 and plastering material is applied directly to the expanded metal lath.

Suitable straps (not shown) may be secured to the frame section members to. support electrical outlet boxes and the like, and in instances where pipes or conduits are required to be passed vertically through the wall, the frame sections are made thick enough to accommodate the same.

The dead air spaces within the frame sections may be filled with suitable insulation (not shown) and it will be noted that the construction of the wall in accordance with the invention renders the same fire-resistant, termite-resistant, and resistant to winds up to tornado velocity.

While in the foregoing there have been described and shown the preferred embodiments of the invention, various modifications may become apparent to those. skilled in the art to which the invention relates. Accordingly, it is not desired to limit the invention to this disclosure and various modifications may be resorted to, such as may lie within the spirit and scope of the appended claims.

What is claimed as new is:

l. A prefabricated metallic frame section adapted tov horizontally span and be attached to aplurality of spaced vertical uprights and support a set of wall forming panels, said frame section including a horizontal flange adapted to be disposed between adjacent upper and lower edges of vertical wall forming panels and to. supportably engage the lower edge of the relatively higher panel, said flange having inner and outer longitudinal edges, a set of substantially T-shaped tabs struck out from said flange, certain of said tabs being angulated upwardly and others downwardly relative to the flange in a plane spaced intermediate said inner and outer edges, the upwardly angulated tabs constituting abutment means for inside surface of the relatively higher panel and the downwardly angulated tabs constituting abutment means for inside surface of the relatively lower panel, the formation of said tabs providing substantially T-shaped recesses in said flange each having an open arm at the outer edge of the flange, outer edge portions of the flange at opposite sides of the open arms of said recesses being deformable into engagement with the panels. and constituting detents therefor, and a horizontal abutment rib connected to and spaced vertically from said flange, said rib having an outer panel abutting edge vertically coplanar with said tabs.

2. A prefabricated metallic frame section adapted to horizontally span and be attached to a plurality of spaced vertical uprights and support a set of wall forming panels, said frame section including a horizontal flange adapted to be disposed between adjacent upper and lower edges of vertical wall forming panels and to supportably engage the lower edge of the relatively higher panel, said flange having inner and outer longitudinal edges, a set of substantially T-shaped tabs struck out from said flange, certain of said tabs being angulated upwardly and others downwardly relative to the flange in a plane spaced intermediate said inner and outer edges, the upwardly angulated tabs constituting abutment means for inside surface of the relatively higher panel and the downwardly angulated tabs constituting abutment means for inside surface of the relatively lower panel, the formation of said tabs providing substantially T-shaped recesses in said-flange each having an open arm at the outer edge of the flange, outer edge portions of the fiangeat opposite sides of the open arms of said recesses being deformable into engagement with the panels and constituting detents therefor, a vertical-flange rigid with said horizontal'flange, and a horizontal rib provided on said vertical flange in vertically spaced relation from the horizontal flange, said rib having an outer panel abutting edge vertically coplanar with said tabs.

3. A metallic frame section for supporting wall panels, said "frame-section comprising a horizontal flange having a. pair of longitudinal side edges, tabs struck out from said flange, certain of said tabs being angulated upwardly and others downwardly relative to the flange in a plane spaced intermediate said side edges, formation of said tabs providing recesses in said flange, said recesses having a relatively wide inner portion and a relatively narrow outer arm open at one of said side edges, portions of said flange at opposite sides of the open arm of said recesses being deformable from the plane of the flange, and an elongated abutment rib connected-l to and disposed in spaced parallel relation from said flange, said rib having a free longitudinal side edge coplanar with said tabs.

4. The device defined in claim 3 together with a second flange provided perpendicularly to the first mentioned flange at one of said side edges of the latter, said rib being provided on said second flange.

References Cited in the file of this patent UNITED STATES PATENTS FOREIGN PATENTS Great Britain Aug. 15, 

